Wastegate Porting – Questions for those who have done it

[Peter_W]

I've read through the Wiki and the various threads - great information. I have some questions.

I have new: exhaust manifold gasket and the copper washers for the oil and water pipe fittings.
Questions: will I need a new gasket for the wastegate manifold to turbo? Will I need a new EGR gasket?

My understanding from the Wiki is that the exhaust manifold, turbo, wastegate manifold, and PCE come out as an attached assembly. To port the wastegate, the wastegate manifold is separated from the turbo.
Question: the Wiki reassembly procedure includes attaching the pre-cat (or PCE) to the wastegate manifold. Why would these have been separated?

Thanks!

[steve matthews]

Because many members hollowed out the pce for better flow.
The copper gaskets I have found to be good to re-use.
Steve

[Peter_W]

Thanks Steve. Having replaced the pre-cat with a PCE years ago I didn't make the mental connection with doing that concurrently with porting the wastegate. What brings me to the need to port the wastegate now is I recently installed a 2 1/2” mandrel bend exhaust and at WOT have to short shift before 4,000 rpm to avoid the dreaded fuel cut. As I don't have time right now to do it myself, I'm going to bring it to my mechanic and so I'm attempting to bring him the items known to be needed. Following are the 4 gaskets I'm questioning if I will need new. The pics are from SJ Sports Cars website and so hopefully they're in stock if I need them. I could just order them all, but if the experience has been that the existing ones can be re-used I can get the project going now instead of waiting for shipping from across the pond. Thanks.

A100E6098S - gasket, turbo to waistgate manifold:


A100E6445S - gasket, oil drain pipe to turbo:


A100E6109S - gasket, egr valve:


A100E6494S - gasket, egr pipe to exhaust manifold:

[Brit-Car-Nut]

Peter: There is always DBE for things like those:

They are in their price book at the prices quoted, but I don't have any way to know if the actually have them in stock.

A100E6098S - $25.96 (£13.74 or approx. $22.67 from SJS + Postage + waiting for delivery ...) I only add this because sometimes DBE is very expensive, but these are reasonable, considering the option.
A100E6445S - $3.50
A100E6109S - $2.53
A100E6494S - $9.60

email me if you want me to find out the best price I can get them for. Sometimes, DBE gives me a "dealer" discount.

[Peter_W]

Thanks John! I've ordered and received good service from DBE on previous occasions - since they don't have an online catalog I often forget (like this time) to think of them first. I'll give them a call to see what's in stock (I won't ask to 'trade on' your relationship with them for these small ticket items - I'd save that for a bigger item )

[HJ2]

I re-used these many times:

A100E6098S - gasket, turbo to waistgate manifold:


A100E6445S - gasket, oil drain pipe to turbo:


A100E6109S - gasket, egr valve:

Although the last 2 ones are cheap to replace so if you have time to order i see no use not replacing them.
I clean the turbo to wastegate seal and apply a very thin layer of copaslip before re-using it


Good luck!

[dapinky]

[Peter_W]

I re-used these many times:

A100E6098S - gasket, turbo to waistgate manifold:


A100E6445S - gasket, oil drain pipe to turbo:


A100E6109S - gasket, egr valve:

Although the last 2 ones are cheap to replace so if you have time to order i see no use not replacing them.
I clean the turbo to wastegate seal and apply a very thin layer of copaslip before re-using it


Good luck!

Thank you! That's very helpful information.

[Peter_W]

I've had my wastegate ported to 22mm as my exhaust has been opened to the higher end of the scale (PCE, 2 1/2" with mandrel bends, flanged section to substitute for the cat during non-public road use only ) I'll post results/impressions after it goes back together this week.

Just for fun, here are some relative comparisons of the stock 16 vs 20, 21, and 22 mm (relative to each other, as obviously the size will vary from screen to screen):

[steve matthews]

Peter you can also clean up the interior of the exhaust manifold and
the turbo housing prior to the wastegate. Look closely and you will see
much iron where it is not needed causing a hazard to flow.

Steve

[Peter_W]

Thanks Steve - I'll check it out. This particular project is not a DIY so I'm paying by the hour...but the "you're already there" criteria applies so I'll look at having that done.

[Peter_W]

Blissful, overboost free acceleration!

But not right off...

...Plug gaps are like children and weeds...turn your back on them for awhile and they'll get big while you're not paying attention.
Put in NGK BKR6EIX and gapped them to .8mm and all is good

[steve matthews]

Yes you will now be able to eat spark plugs.

Steve